Filter element having a cut-out

ABSTRACT

The invention relates to a single serve capsule (1) for producing a beverage, comprising a capsule body (2). Said capsule body has a capsule bottom (3), a sidewall (22), a collar edge (5), and a cover (6). A cavity (100) for accommodating a beverage substrate in the form of a powder, granules, cut leaves or liquid is formed between the capsule bottom and the cover. A filter element (7) is arranged in the cavity, and the filter element is produced of non-woven fiber material. The filter element has a cut-out in which no filtering material is provided. The present invention also relates to a method for producing a single serve capsule.

The present invention relates to a portion capsule for the production of a beverage, having a capsule body having a capsule base, a side wall and a collared periphery and a lid, wherein a cavity for receiving an pulverulent, granulate, cut-leaf shaped, or liquid beverage substrate is configured between the capsule base and the lid, and wherein a filter element is disposed in the cavity and the filter element is made from a fiber material. The present invention furthermore relates to a method for the production of a portion capsule.

Such portion capsules are known in general from the prior art, for example from WO 2012/038063, and are used for the production of tea or coffee beverages in automatic brewing apparatuses, for example. To this end, water is forced through the portion capsule by a pump, and a beverage substance herein is dissolved and/or extracted. However, the portion capsules that are known from the prior art do have the disadvantage that said portion capsules, in particular the filter element, have a comparatively high loss of pressure, that is to say that the positive pressure that has to be made available by the pump of the automatic brewing apparatus has to be substantially higher than 2 bar, and/or that the production of the portion capsules is complex, and/or that said portion capsules have a comparatively high weight.

It was therefore the object of the present invention to provide a portion capsule having a filter element, said portion capsule when compared to the prior art having a minor pressure loss.

This object is achieved by a portion capsule for the production of a beverage, having a capsule body having a capsule base, a side wall and a collared periphery and a lid, wherein a cavity for receiving a pulverulent granulate, cut-leaf shaped and/or liquid beverage substrate is configured between the capsule base and the lid, and wherein a filter element which has a cut-out in which no filtering material is provided is disposed in the cavity.

The explanations made in the context of this subject matter of the present invention apply equally to the other subject matter of the present invention, and vice versa.

The portion capsule according to the invention has the advantage that said portion capsule is comparatively easy to produce, has a large filter area having a minor pressure loss, and has a comparatively minor weight.

The portion capsule in the context of the present invention comprises a portion capsule that is preferably hermetically tight. This means that the beverage or foodstuff substrate, for example coffee powder, soup powder, or tea, that is located in the portion capsule prior to the extraction and/or dissolving procedure in relation to the environment is closed in a substantially aroma-tight manner. However, the portion capsule does not have to be hermetically tight but, prior to the use of said portion capsule, can also be provided in a hermetically tight packaging which then is opened, for example manually. Such portion capsules are typically opened at least on one side, preferably two sides, that is to say able to be percolated by the preparation liquid without said portion capsule being broached.

The portion capsules for the production of a beverage or of a foodstuff are preferably shaped in the manner of a truncated cone or a cylindrical manner, and are produced for example from a vacuum-formed plastic film or by the plastic injection-molding method. Said portion capsules usually have a closed capsule base and an open filling side having a collared periphery onto which a film lid is sealed or adhesively bonded once the cavity of the portion capsule has been provided with a filter element and has been filled with a granulate and/or leaf-shaped and/or cut-leaf shaped and/or pulverulent and/or liquid beverage substance.

A filter element which prevents the beverage substrate making its way into the prepared beverage or foodstuff is provided between the capsule base and the beverage substrate. This filter element is produced from fibers and according to the invention now has a cut-out in which no filtering material is provided. This cut-out preferably has an external diameter of 3 to 15 mm. The external diameter of the cut-out is preferably 5 to 40% of the available internal diameter of the capsule body in the region of the capsule base. Weight is saved by way of the cut-out. The cut-out can be employed for aligning the filter element in relation to the capsule body. The cut-out of the filter element is preferably provided in the region of the base of the portion capsule, and the peripheral region of the cut-out is preferably connected to the base of the capsule body. The cut-out is preferably located in the region of the center of the filter element. The filter element is preferably provided so as to be at least substantially rotationally symmetrical. The cut-out is particularly preferably located about the symmetry axis, particularly preferably so as to be rotationally symmetrical about the symmetry axis. The cut-out is preferably configured to be circular.

According to one further subject matter according to the invention or preferred subject matter of the present invention, the filter element is tack-welded to the capsule body.

The explanations made in the context of this subject matter of the present invention apply equally to the other subject matter of the present invention, and vice versa.

Tack-welded in the context of the local invention means that the filter element is connected to the capsule body but that this connection is performed only in a punctiform and/or portion-by-portion manner in relation to the circumference of the filter element, such that this connection does not have any liquid-sealing effect; rather, liquid can flow between two tack-welded locations. For example, the filter element along an annulus is connected to the capsule body only at a few locations and not in a continuous manner. This embodiment of the present invention has the advantage that in particular in the case of large filter elements or of filter elements that are suspended in the capsule body the filter element can be imparted a specific shape by way of which it is prevented, for example, that the filter element comes into contact with a broaching member. Moreover, the pressure loss of the filter element can be reduced by way of the tack-weld, and/or the filter area can be enlarged. The filter element can be tensioned by way of the tack-weld. Tack welding is preferably performed by way of sealing, preferably using ultrasound.

The filter element is disposed between the beverage substrate and the capsule base and/or the side wall of the capsule body, and preferably has a first and a second end which are particularly preferably mutually spaced apart, are in particular mutually separated by the side wall of the filter element. The water flows into the filter element in the region of the one end. The filter element preferably has a side wall through which the prepared beverage is at least in part drained. This side wall of the filter element at least in portions preferably runs parallel with the side wall of the capsule body. The side wall of the filter element can bear on the side wall of the capsule body. The side wall is preferably shaped in the manner of a truncated cone, or has a portion shaped in the manner of a truncated cone, or is provided to be parabolic. The filter element by way of the other end is preferably connected to the base of the capsule body. The filter element particularly preferably has a peripheral region which particularly preferably adjoins the first end of the filter element in an annular manner. The side wall is provided so as to be at an angle in relation to the peripheral region. The side wall and/or the peripheral region preferably have/has folds, and/or the filter element is vacuum-formed, that is to say said filter element while applying pressure and/or temperature is formed from a planar semi-finished product into a three-dimensional structure. The material thickness within the filter element preferably changes in vacuum-forming, and/or the arrangement of the fibers is modified. A central region which at least in portions preferably runs parallel with the base of the capsule body and/or is located in the region of the rotation axis of the filter element adjoins the side wall of the filter element in the base region of the capsule body. The cut-out of the filter element is preferably located in the central region. This central region is preferably connected to the base of the capsule body.

The side wall of the filter element when being fastened to the capsule base is preferably tensioned.

The filter element in the region of the first end thereof is connected to the capsule body. This connection is preferably performed in a materially integral manner, in particular by welding, preferably by ultrasonic welding. The connection can be performed in the region of the collared periphery and/or in the region of the side wall of the portion capsule. The filter element is preferably connected to the capsule body also in the region of the second end of said filter element, in particular connected to the internal side of the capsule base. At least one connection is preferably provided so as to be annular. At least one connection, particularly preferably both connections, is/are water-impermeable.

The circular or annular seal in the base region of the portion capsule preferably has an external diameter of 16 to 18 mm. The external diameter of the seal is preferably 5 to 45% of the available internal diameter of the capsule body in the region of the capsule base. The width of the sealing seam is preferably 0.5 to 2 mm.

The filter area is preferably between 1100 and 20,500 mm², particularly preferably between 2000 and 10,000 mm², and most particularly preferably between 6100 and 6900 mm².

The end of the filter element that is connected to the internal side of the capsule base is preferably flared. This flared feature can be performed by heating and subsequent forming and/or by an elastic deformation which is then in terms of the shape thereof stabilized by sealing.

The side wall of the filter element is preferably tensioned. On account thereof, the filter element, in particular the wall region of the latter, is imparted a specific shape which has a positive effect on the flow rate of the water through the filter and/or prevents the filter element being pierced by a broaching member, in particular in the region of the capsule base.

The filter element is preferably produced from a non-woven fiber material, for example from a nonwoven material and/or felt, and prevents particles of the beverage substrate making their way into the beverage to be produced. The filter element can be provided in multiple plies, wherein the plies are preferably interconnected, for example by calendaring. One component part of the filter element is preferably paper and/or plastic and/or a naturally occurring material and/or a biologically degradable plastic and/or a plastic preferably from a sustainable raw material. PE and/or PP are preferred component parts of the fibers.

The filter element is preferably configured so as to be elastic. The side wall of the filter element can be tensioned on account thereof. A change in the shape of the filter element under the pressure of the liquid is at least minimized on account thereof.

In order for the portion capsule according to the invention to be produced, a capsule body is provided, the peripheral region of the filter element or the side wall of the filter element being sealed to the collared periphery or to the side wall of said capsule body, for example. Thereafter, the central region of the filter element is sealed to the capsule base, and the beverage substrate is subsequently filled into the capsule body. The portion capsule is subsequently closed with a film lid which is connected in particular by sealing to the peripheral region of the filter element and/or to the collared periphery of the capsule body. Alternatively, the filter element is connected to the capsule base and filled with the beverage substance. Finally, the film lid is sealed to the peripheral region of the filter element and in a substantially simultaneous manner, the peripheral region of the filter element is connected to the collared periphery of the portion capsule. The filter element herein is preferably tensioned. Potentially projecting material of the filter element can in particular subsequently be removed, for example by punching.

In order for a beverage, for example a coffee beverage, to be prepared, the portion capsule is incorporated in a brewing chamber of a preparation apparatus. After or during the closing procedure of the brewing chamber, the capsule, preferably on the closed base side thereof, is preferably opened by means of an opening mandrel that is disposed in the brewing chamber, wherein the opening mandrel preferably opens the peripheral region of the capsule base. After and/or when sealing the brewing chamber, the filling side of the portion capsule that is closed by way of a film lid is preferably opened by means of at least one piercing means. However, there are also portion capsules which are already opened at least on one side prior to being introduced into the preparation apparatus. A preparation liquid, preferably hot water, is subsequently conveyed under pressure through the film lid into the portion capsule. The preparation liquid percolates the beverage substrate and extracts and/or dissolves the substances that are required for the production of the beverage from the beverage substrate. The beverage thereafter flows through the filter element and from there into the capsule body, said beverage exiting the latter through an opening in the base region. In the case of the portion capsule according to the invention, a pump pressure of approx. 2 bar or less is sufficient in order for water to be conveyed through the portion capsule for the preparation of a coffee.

Yet another subject matter of the present invention is a method for the production of the portion capsule according to the invention, in which method the fitter material is formed and the first end and the second end are connected to the capsule body.

The explanations made in the context of the method according to the invention equally apply to the portion capsule according to the invention, and vice versa.

A cut-out can be incorporated into the filter material prior to, during, or after forming. The cut-out can be established by removing material, for example by means of cutting. However, a semi-finished product made from filter material can also already be pre-formed such that a cut-out results in the filter element in the forming of the filter. Furthermore alternatively, the configuration of the cut-out can be performed in an vacuum-forming procedure.

The filter element is preferably provided so as to be three-dimensional. For example, said filter element at least in portions is designed in the shape of a truncated cone or in a parabolic manner. According to one preferred embodiment of the present invention, the originally planar filter material is formed, in particular rolled and/or folded and/or elongated in an elastic or plastic manner in order for the filter element to be produced.

One end of the filter material, in particular the end in the region of the base of the capsule body, is preferably flared. The flared feature preferably extends about the cut-out in the fitter material, in particular in the central region of the filter element. This flared feature is preferably established by a plastic and/or elastic deformation, for example under the influence of pressure and/or temperature.

The flared feature is preferably connected to the capsule base, in particular by welding, particularly preferably by ultrasonic welding.

The first end of the filter element, the water flowing into the filter element through the opening of said end, is preferably connected to the side wall and/or to the collared periphery of the capsule body, in particular by sealing, in particular by hot sealing, or welding, particularly preferably by ultrasonic welding on the side wall and/or on the collared periphery.

The filter element when being fastened to the capsule body is preferably tensioned.

The sealing seams for fastening the filter element to the capsule body are preferably disposed at least in part in a sequential manner.

According to one preferred embodiment of the present invention, the production of the sealing seams is performed by ultrasonic sealing by way of at least one sonotrode. The sonotrode is preferably brought into contact with the filter material through a radial widening in the region of the first sealing seam. The sonotrode is preferably brought into contact with the filter material in the base region by way of a movement of the sonotrode that is parallel with the central axis of the capsule body. The filter material is preferably formed and/or tensioned by way of the sonotrode.

Exemplary embodiments of the invention are illustrated in the figures and are explained in more detail in the description hereunder. The figures are described in a merely exemplary manner and do not limit the general concept of the invention. The description applies equally to all subject matter of the present invention.

FIG. 1 shows a longitudinal section through a portion capsule according to the prior art, said portion capsule being configured for the preparation of espresso.

FIG. 2 shows a longitudinal section through a portion capsule according to the embodiment as per FIG. 1, said portion capsule lying in a closed brewing chamber.

FIGS. 3-5 show in each case one embodiment of the filter element.

FIGS. 6-9 show in each case the portion capsule according to the invention.

Same parts are at all times provided with the same reference signs in the various figures and therefore are typically also referred to or mentioned only once, respectively.

An embodiment of a portion capsule 1 according to the prior art is illustrated in FIG. 1. The portion capsule 1 comprises a capsule body 2 in the shape of a truncated cone, having a closed capsule base 3 and a collared periphery 5 which is disposed at the filling side 4 of said capsule body 2 and onto which a film lid 6 is welded, sealed, or adhesively bonded. A cavity 100 which is filled with a pulverulent and/or granulate and/or cut-leaf shaped beverage substance 101 and which is preferably closed in an air-tight and aroma-tight manner is thus configured between the capsule base 3 and the film lid 6. The beverage substance 101 herein comprises, for example, a coffee, cocoa, tea, and/or milk powder (or granulate, respectively). A filter element 7, composed from a non-woven fiber material, is preferably disposed on the internal side 3 a of the closed capsule body base 3, that is to say within the cavity 100. In the case of the portion capsule according to the invention the filter element is preferably not planar and will be explained by means of FIGS. 3 to 5.

A portion capsule 1 according to the one in FIG. 1 is illustrated in FIG. 2, wherein the portion capsule 1 in FIG. 2 is disposed in a closed brewing chamber 8. The brewing chamber 8 is composed of a first brewing chamber element 9 and of a second brewing chamber element 10, wherein the first brewing chamber element 9 in order for the portion capsule 1 to be introduced is provided so as to be movable in relation to the second brewing chamber element 10, or vice versa. A gasket 11 is disposed between the two brewing chamber elements 9, 10. The first brewing chamber element 9 is composed substantially of a closing piston 12 having piercing elements 13 a, 13 b for opening the film lid 6 of the portion capsule 1, of a preparation liquid infeed 14, and of the gasket 11. The second brewing chamber element 10 is composed substantially of a brewing chamber dome 15 that partially encloses the portion capsule 1 and has an opening mandrel 16 that is disposed on the base of the brewing chamber dome 15 and is provided with discharge grooves 17 and with a beverage drain 18, for example. In order for the portion capsule 1 to be received, the brewing chamber 8 is in an open state (not illustrated) in which the first and the second brewing chamber element 9, 10 are mutually spaced apart in order to guarantee infeeding of their portion capsule 1, and in the closed state illustrated, in which a preparation procedure for the production of a beverage by means of the portion capsule 1 can be carried out. The brewing chamber 8 in the closed state is closed in a pressure-tight manner. When the brewing chamber 8 is transformed from the open state to the closed state depicted, the film lid 6 is pierced by the piercing elements 13 a, 13 b such that preparation liquid, in particular hot brewing water, makes its way, preferably under pressure, through the preparation liquid infeed 14 into the cavity 100 of the portion capsule 1. Furthermore, the capsule base 3 is preferably perforated by the perforation means that is configured as the opening mandrel 16 when the brewing chamber 8 is being closed such that an exit opening 107 is preferably generated in the portion capsule 1 through which the prepared beverage liquid can exit from the portion capsule 1 in the direction of the beverage drain 18. In order for the discharge of the beverage liquid to be supported, the opening mandrel 16 on the shell face thereof here has the discharge grooves 17. The brewing chamber illustrated is in principle suitable for the production of a beverage or foodstuff, using the portion capsule according to the invention which is described by means of FIGS. 6 to 8.

FIG. 3 shows a first embodiment of the filter element 7 of the portion capsule according to the invention, said filter element 7 in the present case being configured in the shape of a truncated cone. A person skilled in the art understands that the filter element can however also have another shape. The filter element defines a cavity in which the beverage substrate will be provided. The filter element has a first end 28 through which the water in the present case flows in and dissolves and/or extracts ingredient substances of the beverage substrate which is located within the filter element. The prepared beverage exits the filter element 7 in particular by way of the side wall 7′″ of the filter element, flows into the capsule body, and from there through an opening into a container, for example a cup. The filter element according to the invention on the second end 29 thereof, in particular in the central region 7″ of the filter element, has a cut-out 24. This cut-out preferably extends in a rotationally symmetrical manner about a central axis of the filter element. The cut-out is preferably circular. There is no woven filter fabric in the region of the cut-out.

FIG. 4 shows a further embodiment of the filter element 7, wherein reference can be made substantially to the explanations according to FIG. 3. In the present example, the filter element in the region of the second end 29 thereof has a flared feature 7″″ which has been produced by a plastic and/or elastic deformation of the filter element, for example under the influence of pressure and/or heat. The flared feature projects at an angle from the filter element, here in an outward manner, and can be used for fastening the filter element to the base of the portion capsule. Moreover, the flared feature stabilizes the shape of the filter element in the region of the cut-out.

FIG. 5 shows yet one more embodiment of the filter element, wherein reference is made to the explanations according to FIGS. 3 and 4. The flared feature in the present case is directed inward and can thus be connected to the capsule base.

FIG. 6 shows a first embodiment of the portion capsule according to the invention. The filter element in the present case has a peripheral region 7′ which is provided at an angle in the region of the first end 28 of the filter element and in the present case is connected by means of the seal 25 to the collared periphery 5 of the portion capsule. The seal preferably extends in an annular manner. The second end 29 of the filter element is connected to the base region of the capsule by way of a seal, here an annular seal. The seal extends in an annular manner about the cut-out 24 of the filter element 7. As is illustrated by the arrow 22, the liquid, presently water, flows into the filter element and extracts or dissolves, respectively, the substances of the beverage substrate that are required for the production of the beverage. The prepared beverage flows into the portion capsule, as is illustrated by the arrow 26, and from there flows through the capsule base out of the portion capsule. Liquid does not run out of the cut-out 24. The filter element is preferably tensioned.

FIG. 7 shows a further embodiment of the portion capsule according to the invention, wherein reference can substantially be made to FIG. 6. The filter element in the present case has no peripheral region 7′. The side wall of the filter element here is connected to the capsule body by way of an annular seal 25.

In the case of both embodiments according to FIGS. 6 and 7 a flared feature which preferably by means of a seal, in particular an ultrasonic seal, is connected to the base of the capsule body can be provided in the peripheral region of the cut-out 24. The filter element, when being incorporated into the capsule body, is preferably tensioned. Furthermore preferably, the sealing seams in the base region and in the peripheral region, or on the side wall of the capsule body, respectively, are attached in a sequential manner. Both sealing seams are preferably made by a sonotrode, wherein the sonotrode can also shape the filter element. The sonotrode preferably penetrates the cut-out 24 of the filter element at least in part.

FIG. 8 shows yet another embodiment of the portion capsule according to the invention. The filter element in the present case is also connected to the capsule body by tack-welded points 27 between the two seals 25, 30. These tack-welds have the advantage that the filter element can be stabilized in a very specific shape, but that the filter area above the tack-welding nevertheless can participate in the filtering procedure. The seal 30 is optional in this embodiment of the portion capsule. The filter element 7 can optionally have the cut-out 24.

FIG. 9 shows yet another embodiment of the portion capsule according to the invention. In this case, the base region has a convexity. The filter element with or without the cut-out can be connected to the circumference and/or to the surface, in particular by welding or sealing. The surface can be embodied so as to be planar or curved.

In the case of all exemplary embodiments, the capsule can be opened by broaching, in particular by broaching the base region. However, it is also conceivable for the portion capsule, in particular the base region thereof, to be pre-perforated ex-works, wherein these pre-perforated holes are preferably closed by way of an aroma-tight fibs which is removed prior to the use of the portion capsule.

LIST OF REFERENCE SIGNS

-   1 Portion capsule -   2 Capsule body -   3 Capsule base -   3 a Capsule base internal side -   3′ Peripheral region of the capsule base -   4 Filling side -   5 Collared periphery -   6 Lid, film lid -   7 Filter element -   7′ Peripheral region of the filter element -   7″ Central region of the filter element -   7′″ Side wall of the filter element -   7″″ Fastening face, flared periphery -   8 Brewing chamber -   9 First brewing chamber element -   10 Second brewing chamber element -   11 Gasket -   12 Closing piston -   13 a Piercing element -   13 b Piercing element -   14 Preparation liquid Infeed -   15 Brewing dome -   16 Opening mandrel -   17 Discharge grooves -   18 Drain -   19 Piercing tip -   20 Concavity -   21 Concavity/convexity -   22 Side wall -   23 Brewing dome base -   24 Cut-out -   25 First annular fastening, first annular seal, first seal -   26 Prepared beverage -   27 Tack-weld -   28 First end of the filter -   29 Second end of the fitter -   30 Second annular fastening, second annular seal second seal -   31 Flared feature -   100 Cavity -   101 Beverage substrate -   106 Central point -   107 Opening, exit opening 

The invention claimed is:
 1. A method for production of a portion capsule comprising: having a capsule body having a capsule base, a side wall and a collared periphery and a lid, wherein a cavity for receiving a pulverulent granulate or liquid beverage substrate is configured between the capsule base and the lid, wherein a filter element that is produced from fibers is disposed in the cavity, wherein the filter element has a cut-out in which no filtering material is provided, and wherein the filter element is formed, wherein the filter element has a first end and a second end, wherein the first end and the second end are connected to the capsule body, and wherein the first end and/or the second end is flared at a flared feature.
 2. The method as claimed in claim 1, wherein the filter element is tack-welded to the capsule body.
 3. The method as claimed in claim 1, wherein the filter element is vacuum-formed.
 4. The method as claimed in claim 1, wherein the first end and the second end of the filter element are in each case sealed to the capsule body.
 5. The method as claimed in claim 1, wherein the first end and the second end of the filter element are connected to the capsule body by way of an annular seal.
 6. The method as claimed in claim 5, wherein an external diameter of the annular seal at the second end is about 16 to about 18 mm.
 7. The method as claimed in claim 1, wherein the filter element is sealed in a region of the flared feature.
 8. The method as claimed in claim 1, wherein material of the filter element is tensioned.
 9. The method as claimed in claim 1, wherein the filter element has a portion in a shape of a hollow cone.
 10. The use of a portion capsule as claimed in claim 1, for the production of a coffee, cocoa, tea, and/or milk beverage.
 11. The method as claimed in claim 1, wherein the material of the filter element is rolled and/or folded.
 12. The method as claimed in claim 1, wherein the flared feature is connected to the capsule base.
 13. The method as claimed in claim 1, wherein the first end is connected to the side wall and/or to the collared periphery of the capsule body.
 14. The method as claimed in claim 13, wherein the filter element when being fastened to the capsule body is tensioned.
 15. The method as claimed in claim 1, wherein sealing seams are disposed in a sequential manner.
 16. The method as claimed in claim 1, wherein sealing seams are established by ultrasonic sealing by way of at least one sonotrode.
 17. The method as claimed in claim 16, wherein the sonotrode is brought into contact with the material of the filter element through a radial widening in a region of the sealing seams.
 18. The method as claimed in claim 16, wherein the sonotrode is brought into contact with the material of the filter element in a base region by way of a movement that is parallel with a central axis of the capsule body.
 19. The method as claimed in claim 1, wherein the filter element is formed and/or tensioned by way of a sonotrode. 